Papers by Keyword: Seam Weld

Abstract: The material flow in porthole dies is of crucial importance with regard to the seam weld quality in aluminum extrusion. Thus, experimental as well as numerical investigations on the effect of die geometry on the material flow were conducted. The experimental tests were performed on a 10 MN laboratory extrusion press. During the experimental trials, the extrusion ratio was varied by means of exchangeable die plates. Since the modular die allows removal of the aluminum in the welding chamber as well as in the feeders after the process, the material flow could be inspected in detail. The experimental results were used to improve the accuracy of FEA simulations, which were also conducted by commercial software. An attempt was made to improve the result quality of Eulerian FEA model regarding the simulation of an extrusion process with a gas pocket in the welding chamber. The influence of the modeling approach on the predicted material flow and on the contact pressure was analyzed and finally linked to the seam weld quality.

Abstract: A new weld seam detection based on the genetic algorithm has been presented. Firstly, the experimental platform has been setup, and the welding images can be captured by the CCD camera in real time. On this basis, the process region, which is in front of the weld pool, has been determined. Then the median filter has been applied to reduce the disturbance of the noise producing during the welding period. Moreover, the GA has been deeply researched and applied to the weld seam detection. In the end, some experiments have been caught out, and the results show that compared with the traditional Ostu process method, the weld seam images, which are processed by the genetic algorithm, are more clearer and have less noise, which can meet the satisfy of auto welding system.

Abstract: The accurate simulation and the optimization of extrusion processes can be a helpful technique to ensure producibility of complex aluminum profiles, for example for the automobile industry. Currently, the die designing is based on expert’s knowledge and cost-intensive prototyping. The paper deals with numerical investigations based on finite element simulations as well as experimental investigations of an industrial extrusion process. A newly developed method for longitudinal seam weld prediction is applied to analyze the position of the longitudinal welding line and the welding quality.

Abstract: The increasing attention to magnesium alloys in extruded profiles, especially in the transportation industry, is related to their low density associated with good mechanical properties and complete recyclability. This allows to push towards both increasing efficiency and pollution restrictions. However, these advantages are negatively balanced by the production rates drop in relation to dangerous profile temperatures increasing that force to keep low velocities. In this context, a novel porthole die has been purposely designed for magnesium alloys allowing an increasing of the process velocity up to four times with respect to past solutions. The mandrel consisted of three ports made by 120° bridges that created an equal number of seam welds. The extruded tubes, made in ZM21, were 50 mm in diameter and 2 mm in thickness and were tested under different process conditions. In the present work, the quality of the seam welds has been investigated in relation to each process condition by means of the rubber plug testing method that allowed to applied an hydrostatic tensile state.

Abstract: Although the extrusion process is regarded as a continuous process, in practice billets are discretely loaded into the press. The joining of two consecutive billets is guaranteed by the high hydrostatic pressure of the process. Nevertheless, mechanical proprieties of the profile in the welded region are lower than those of the adjacent area thus leading to the discarding of the welded segment. Extension of the segment is mainly affected by the interaction of seam and charge welding phenomena and, nowadays, its prediction is still a tricky task involving rough empirical relations or labour intensive analyses. Aim of this work was to identify the starting and exhausting points of the charge welds evolution inside an industrial multi-profiles die, in order to determine the exact position and the minimal length to be scraped. The extrusion of four AA6060 hollow profiles through a multi-hole die were preliminary monitored in an industrial press by accurate recording of the process loads, temperatures and speeds during the process. The four profiles were sectioned starting from the ‘stop mark’ then grinded and etched in order to investigate the location and the dimension of the zone to be ridded. While the experimental activity is detailed elsewhere, this paper is focused on the finite element modelling of the process. The numerical simulation was performed by means of the Altair HyperXtrude code and predictions compared to experimental data with a particular focus on the computation of the charge evolution. It was found a good agreement both in terms of general trend and prediction of the exhausting points so thus proving the code to be a reliable tool for an accurate determination of the scraps.

Abstract: This article firstly established two finite element models of seam weld and spot-weld for the front sub-frame, then used the two models for seam weld and spot weld fatigue simulation analysis, next cooperated with bench test results for verification. After the above steps, we not only found the weak portion of the front sub-frame, but also provide reference for both optimum design and improving the bench test design.

Abstract: In contrast to conventional extrusion processes, where a lot of research is done on in the welding quality, in composite extrusion, research is investigated into the welding line positioning. As a result of the process principle, the reinforcing elements are embedded into the longitudinal welding line. Hence, an undefined material flow inside the welding chamber induces reinforcement deflection, which can lead to reduced mechanical properties, as momentum of inertia. Therefore and to reduce costly experimental investigations, a new method of an automated numerical welding line prediction was developed. The results form HyperXtrude finite element calculations are used for special particle tracing simulations to predict the welding line in the profile cross section accurately. The procedures of segmentation and characteristic extraction are presented to approximate the welding line by cubic spline functions. The method was fully programmed in the Java program language, and works well for all HyperXtrude process models consisting of tetrahedral elements.

Abstract: During earthquake, the inelastic action in the plastic hinge regions of structures and bridges results in significant reversed deformation and failure of the critical components because of cumulative damage. To simulate seismic behavior of structure members and develop a simplicity damage criterion for circular concrete filled steel tubular (CFT) columns subjected to a series of earthquake excitations, an experimental study was undertaken to investigate the cumulative damage and relationship between low cycle fatigue life and displacement amplitude. Two types of large scale circular CFT columns with different kinds of seam weld and inner concrete compressive strength including nine specimens were tested under quasi static loading with constant and variable cyclic amplitudes. The test data were evaluated with the fatigue model relating deformation and fatigue life. Fatigue life expressions for application in damage-based seismic design are developed.

Abstract: In this paper a review of several papers published on seam weld formation also by the authors is presented and discussed: the process mechanics is deeply investigated and several experimental results are related to process parameters by means of FEM simulations. The relation between die design and local welding parameters, such as contact pressure, temperature, time of contact, strain and strain rate paths is analyzed. In particular, by testing profiles extruded in different conditions, it was found that it is possible to find optimum processing conditions for a welded profile to behave like a not welded one. The possibility to adopt criteria for assessing the welding quality is finally discussed, together with its implementation directly inside process FEM codes.

Abstract: For an increase in safety against crack initiation and growth in metallic structures of airplanes different concepts were developed in the past. In the focus of this work are profiles made of continuously reinforced extruded aluminum. The production and the used die set of these profiles is presented as well as problems occurring in terms of geometrical inaccuracies of the embedded high strength wires. In addition, this paper attends to the problem of lateral seam weld formation. The interface between the AA-2099 as well as AA-6056 aluminum alloy and the high strength wires Nivaflex and Nanoflex were characterized by metallurgic investigations and push-out tests. As a result it can be stated that a sufficient geometrical accuracy could be achieved and a high interface strength can be accomplished even if a slight gap is still present in the interface layer between matrix and reinforcing element.